Fiber Optic Cables and Assemblies for Fiber Toward the Subscriber Applications

ABSTRACT

Disclosed are fiber optic cables and assemblies for routing optical networks closer to the subscriber. The fiber optic cables have a robust design that is versatile by allowing use in aerial application with a pressure clamp along with use in buried and/or duct applications. Additionally, the fiber optic cables and assemblies have a relatively large slack storage capacity for excess length. Assemblies include hardened connectors and/or optical connectors such as plugs and/or receptacles suitable for outdoor plant applications attached to one or more ends of the fiber optic cables for plug and play connectivity.

RELATED APPLICATION

The present application is a Continuation-in-Part of U.S. patentapplication Ser. No. 11/986,705 filed on Nov. 26, 2007, the disclosureof which is incorporated herein by reference.

BACKGROUND

1. Field of the Disclosure

The present invention relates to fiber optic cables and assembliessuitable fiber optic networks such as fiber to the subscriber or fiberto the node applications. More particularly, the present inventionrelates generally to fiber optic cables having a robust design with arelatively large slack storage capacity for excess length along withassociated assemblies for plug and play connectivity.

2. Technical Background

Communications networks are used to transport a variety of signals suchas voice, video, data and the like to subscribers. Service providers arerouting optical fiber deeper into communication networks, therebyincreasing the bandwidth available to subscribers for receiving thedesired content. More specifically, service providers are routingoptical fiber to the premises of subscribers instead of copper, therebydramatically increasing the bandwidth available to subscribers foremerging applications.

FIG. 1 schematically illustrates two preconnectorized fiber optic cables10 and 10′ being routed to a premise of a subscriber using two differentexemplary installation techniques. Specifically, FIG. 1 shows a firstpreconnectorized fiber optic cable 10 being routed to premises 20 in anaerial installation and a second preconnectorized fiber optic cable 10′being routed to premises 20 in a buried installation. In the aerialinstallation, a first end 10 a of preconnectorized cable 10 is attachedat a first interface device 12 located at, or near, a pole 11 and asecond end 10 b of preconnectorized cable 10 is attached at a secondinterface device 14 located at premise 20. By way of example, firstinterface device 12 may be a closure, multiport (a device havingmultiple receptacles), or the like and second interface device 14 may bea closure, network interface device (NID), optical network terminal(ONT), or the like. In the aerial installation, the craft typically usesa pressure clamp 19 (i.e., a p-clamp) as schematically shown in FIG. 1for securing fiber optic cable 10 under tension at, or near, pole 11and/or premises 20, thereby avoiding undue sag in fiber optic cable 10along the aerial span.

FIG. 2 depicts a 2 PR pressure clamp 19 such as available from ReliablePower Products of Franklin Park, Ill. as well as from others with aportion of fiber optic cable 10 disposed therein. Pressure clamp 19includes a body 19 a, a grip 19 b, and a wedge 19 c for clamping (i.e.,squeezing) the fiber optic cable with increasing frictional force as thetension on the fiber optic cable is increased. Body 19 a receives fiberoptic cable 10 between grip 19 b and wedge 19 c and squeezes ittherebetween as tensile forces are applied. Body 19 a also includes aloop end used for attaching it to pole 11, premises 20, or otherstructure. Simply stated, the frictional force on the fiber optic cableincreases as tension force of the fiber optic cable pulls wedge 19 ctighter onto the fiber optic cable, thereby preventing the fiber opticcable from pulling out of the pressure clamp. It is possible for theclamping (i.e., frictional) force from pressure clamp 19 to plasticallydeform the fiber optic cable therein or even severely damage the samesince grip 19 b has dimples and body 19 a has ridges. Pressure clamp 19can not be used with all fiber optic cable designs since it may causedamage and/or elevated levels of optical attenuation. Consequently,other types of devices that do not clamp the optical portion of thefiber optic cable are also used for securing fiber optic cables such aswire vises, winding posts, and the like. Simply stated, conventionalfiber optic cables used with in pressure clamp 19 uses a buffer tube forprotecting the optical fibers while allowing use within whilemaintaining acceptable optical performance and reliability.

In buried or duct applications, the first and second ends ofpreconnectorized cable 10′ are respectively connected to an interfacedevice 16 located at a field location 18 such as inside a pedestal, amanhole, a handhole or the like and second interface device 14. Theinterface devices may include at least one receptacle (not visible) formaking the optical connection with a plug end of preconnectorized fiberoptic cable 10. Like aerial applications, buried or duct applicationscan also require a rugged fiber optic cable design. For instance, thefiber optic cable can encounter rough terrain such as being pushedagainst rocks, or the like or rough handling during installation such aspulling into a duct. Thus, for fiber to the subscriber applications thepreconnectorized fiber optic cable should be robust enough to handleeither an aerial, buried, and/or duct installations while maintainingsuitable optical performance and reliability.

Further, the distance between pole 11, or field location 18, to thesecond interface device 14 at premises 20 varies with each specificinstallation. By way of example, if the distance between pole 11 andsecond interface device is 30 meters, then the craftsman may select a 50meter preconnectorized fiber optic cable 10 for managing the length ofcable for slack storage (i.e., the storage of excess 20 meter length).For instance, the slack cable length may be stored behind the secondinterface device 14, or other suitable location. Because this excesslength for slack storage can take a substantial amount of space, maylook unsightly, and/or there may be a limited space available, thecraft, generally speaking, selects a length of preconnectorized fiberoptic cable from his inventory that minimizes the length for slackstorage for the particular installation. Consequently, the craft carriesmany different lengths of preconnectorized fiber optic cables into thefield to accommodate these varying distances while accommodating theslack storage limitation. For instance, the craft may carry up tofifteen different lengths of preconnectorized fiber optic cables intothe field, which creates complexity issues for the craft, the serviceprovider, and the manufacturer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates the drop link portion of an opticalnetwork being routed to a premises using different installationstechniques.

FIG. 2 is a perspective view of a portion of a fiber optic cable heldwithin a typical pressure clamp used in aerial applications.

FIG. 3 is a cross-sectional view of a fiber optic cable according to thepresent invention.

FIG. 4 depicts a cross-sectional area of the fiber optic cable of FIG. 3superimposed on a conventional fiber optic drop cable.

FIGS. 4 a-4 c depict cross-sectional views of the fiber optic cableswith different height ratios disposed within the pressure clamp of FIG.2.

FIG. 5 is a graph depicting optical delta attenuation for the fiberoptic cable of FIG. 3 along with a comparison fiber optic cable whendisposed within the pressure clamp of FIG. 2 at various tensile loadingconditions.

FIGS. 6 and 7 are cross-sectional views of fiber optic cables havingmultiple optical fibers according to the present invention.

FIGS. 8-10 depict cross-sectional views of fiber optic cables similar tothe fiber optic cable 30 having a tonable element according to thepresent invention.

FIGS. 11 a-11 c shows fiber optic cable of FIG. 3 that waspreconnectorized with an exemplary hardened connector according to thepresent invention in various stages of being plugged into acomplementary receptacle.

FIG. 12 is an assembled perspective view of a preconnectorized fiberoptic cable using the fiber optic cable of FIG. 8 according to thepresent invention.

FIG. 13 is a partially exploded view of the preconnectorized fiber opticcable of FIG. 11 a according to the present invention.

FIGS. 14 a and 14 b respectively depict a perspective view and asectional view of the shroud of the hardened connector of FIG. 13.

FIG. 15 a is a perspective view of the fiber optic cable of FIG. 3prepared for connectorization.

FIG. 15 b is a perspective view of one shell of the crimp housing of thehardened connector of FIG. 13.

FIG. 15 c shows a partially assembled view of the preconnectorized fiberoptic cable of FIG. 13.

FIG. 15 d shows another partially assembled view of the preconnectorizedfiber optic cable of FIG. 13 where the crimp band is being slid intoposition onto the crimp housing.

FIGS. 15 e and 15 f are partially assembled views of differentpreconnectorized fiber optic cable assemblies where the connectorhousing is integrally molded into the housing.

FIG. 16 is an exploded view of another preconnectorized fiber opticcable using a different hardened connector according to the presentinvention.

FIG. 17 depicts partially exploded views of two preconnectorized fiberoptic cables each having a complementary hardened connector according tothe present invention.

FIG. 18 depicts partially exploded views of two preconnectorized fiberoptic cables each having a complementary hardened connector similar tothe hardened connectors of FIG. 17 according to the present invention.

FIG. 19 depicts partially exploded views of two preconnectorized fiberoptic cables each having a complementary hardened connector similar tothe hardened connectors of FIG. 17 according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the present preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings. When practical, the same reference numerals willbe used throughout the drawings to refer to the same or like parts. FIG.3 is a cross-sectional view of a fiber optic cable 30 having at leastone optical fiber 32, a first and a second strength component 34, and acable jacket 38. First and second strength components 34 are disposed onopposite sides of optical fiber 32 and generally aligned along a commonplane A-A, thereby providing a preferential bend characteristic to fiberoptic cable 30. As depicted, cable jacket 38 contacts the optical fiber32 and first and second strength members 34. Cable jacket 38 has amedial height MH disposed about optical fiber 32 that is less than anend height EH of fiber optic cable 30, which is advantageous forpreserving optical performance during clamping within pressure clamp 19as discussed herein. Fiber optic cable 30 is also advantageous becauseit has a relatively small cross-sectional footprint compared withconventional fiber optic drop cables used for fiber to the subscriber,or node, applications, thereby providing a relatively large slackstorage capacity for excess length while still being robust.

For comparison purposes, FIG. 4 schematically depicts a cross-sectionalfootprint 42 of fiber optic cable 30 (represented by solid lines)superimposed onto a cross-sectional footprint 44 for a conventionalfiber optic cable (represented by phantom lines with outlines of thebuffer tube and strength members also shown) for fiber to the subscriberapplications. As shown, the cross-sectional footprint 42 of fiber opticcable 30 is substantially smaller than the cross-sectional footprint 44of conventional fiber optic cable while still providing a robust designfor use within a 2PR pressure clamp 19. Remarkably, cross-sectionalfootprint 42 is about 42% of the cross-sectional footprint 44 (e.g.,about 13.2 millimeters squared compared to about 31.5 millimeterssquared) while still working within pressure clamp 19. Cross-sectionalfootprint 42 is substantially smaller than cross-sectional footprint 44since it does not require a buffer tube (represented by the middlecircle in phantom) for housing and protecting optical fiber 32 when usedwithin pressure clamp 19 like the conventional fiber optic cable.Moreover, fiber optic cable 30 does not require special installationprocedures such as separation or isolation of the optical fiber from theclamping force of pressure clamp 19 such as with other device for aerialapplications. Simply stated, the portion of fiber optic cable 30 havingoptical fiber 32 therein can be placed within pressure clamp 19 whilemaintaining suitable optical performance without having a buffer tube(or other similar structure) for protecting the optical fiber. Likewise,fiber optic cable 30 can also withstand the requirements of buriedand/or duct applications.

By way of example, fiber optic cable 30 has a height H of about 3.0millimeters and a width W of about 5.3 millimeters while still providingsuitable optical performance when subjected to the clamping force ofpressure clamp 19. The concepts of the present invention may be usedwith fiber optic cables having other suitable dimensions and/or shapesas shown in Table 1. Moreover, the smaller cross-sectional footprint offiber optic cable 30 allows for a smaller coil diameter compared withthe conventional fiber optic cable. Consequently, fiber optic cable 30advantageously allows storing relatively long lengths of the same in arelatively small volume (i.e., space) such as at the network interfacedevice at the subscriber's premise, closure, pedestal, or other suitablelocations. Moreover, since longer lengths of fiber optic cable 30 can bestored in smaller spaces the craft can carry fewer lengths ofpreconnectorized assemblies into the field while still accommodatinglimited storage space constraints. In other words, fiber optic cable 30allows relatively large lengths of slack storage in small spaces foraerial installations and/or buried installations, while still providingsuitable optical performance within pressure clamp 19. Moreover, theservice provider and manufacturer can advantageously stock fewer lengthsof preconnectorized fiber optic cables such as a short length and a longlength.

Fiber optic cable 30 is also advantageous because it has a relativelylow weight and small footprint for ice and wind loading such as underNESC heavy loading conditions. As such, lower tensile forces arerequired for maintaining suitable sag for fiber optic cable 30 in aerialinstallations, which results in lower tensile forces being applied tosubscriber's premises from tension forces applied to the pressure clamp.Illustratively, a 1% sag of fiber optic cable 30 in a 150 foot aerialspan may be achieved with a tensile force of about 20 pounds (about a30% reduction in tensile force compared with the conventional fiberoptic drop cable shown in FIG. 4), which also makes fiber optic cable 30easier for the craft to install. Table 1 compares characteristics (i.e.,the overall dimensions, coiling capacity, and weight) of fiber opticcable 30 with the conventional fiber optic cable schematicallyillustrated in FIG. 4 in the first two rows. Table 1 also includes sizevariations of fiber optic cable 30 listed as fiber optic cable 30′ andfiber optic cable 30″ for illustrating the ranges of thecharacteristics. Because conventional fiber optic cable of FIG. 4 hasone or more optical fibers within a 3.0 millimeter buffer tube it has anoverall cable width of about 8.1 millimeters and cable height of about4.4 millimeters.

TABLE 1 Comparison of conventional cable with fiber optic cable 30 andsize variations thereof Overall Volume for coiling 60 Weight width andmeters of fiber optic of cable Cable height (mm) cable (cm³) (kg/km)Conventional cable 8.1 × 4.4 8600 31 Fiber optic cable 30 5.3 × 3.0 430015 Fiber optic cable 30′  5.9 × 3.25 4900 19 Fiber optic cable 30″  5.0× 2.65 3760 13

Specifically, the first two rows of Table 1 shows that 60 meters of thefiber optic cable 30 can be coiled and stored in a space having a volumeof about 4300 cubic centimeters or less, which is half of the volume(i.e., space) required for the same length with the conventional fiberoptic cable. Part of the reason for the increase in slack storage isthat fiber optic cable 30 can be coiled into a smaller diameter comparedwith the conventional fiber optic cable (i.e., fiber optic cable has asmaller bend radius). By way of example, fiber optic cable using 1.25millimeter glass-reinforced plastic can begin being coiled with adiameter of about 12.5 centimeters or less, whereas the conventionalfiber optic cable can begin being coiled with a diameter of about 16centimeters. The other reason that fiber optic cable 30 has a dramaticincrease in the slack storage characteristic is because thecross-sectional area of fiber optic cable 30 is much smaller (i.e.,about 42% of the conventional fiber optic cable area as depicted in FIG.4). Moreover, fiber optic cable 30 has a considerable reduction inweight compared with the conventional fiber optic cable. Specifically,fiber optic cable 30 has a weight of about 15 kilograms or less perkilometer of length compared with a weight of about 31 kilograms perkilometer of length for the conventional fiber optic cable schematicallyillustrated in FIG. 4. This is a dramatic reduction in weight andincrease in storage capacity which is surprising for fiber optic cablesthat are capable of being GR-20, RDUP, IEC, or ICEA compliant. Thus, theslack storage and weight characteristics along with the performance offiber optic cable 30 within pressure clamp 19 (as discussed below)provide the craft with a versatile fiber optic cable design for fiberoptic networks.

Table 1 also lists size variations for fiber optic cable 30 and howchanges in size affect the storage capacity and weight of the design. Asshown by fiber optic cable 30′, if the size increases slightly, then thestorage capacity decreases and the weight increases to about 19kilograms per kilometer or less. Likewise, if the size decreasesslightly, then the space for storage capacity of 60 meters decreases toabout 3760 cubic centimeters or less and the weight per kilometerdecreases as shown by fiber optic cable 30″. Additionally, fiber opticcables according to the invention are useful for other applications inoptical networks such as a tether cable that forms a portion of adistribution fiber optic cable assembly, as a jumper cable assembly,attached to a multiport device, or the like.

Generally speaking, strength members 34 are much larger in size thanoptical fiber 32 and are selected to provide the desired tensilestrength requirements for fiber optic cable 30. By way of example,strength members 34 are dielectric members such as glass-reinforcedplastic (GRPs) having a diameter of about 1.25 millimeters, but othersizes, shapes, and/or materials are possible for the strength members.For instance, strength members 34 can have an oval, rectangular, orother shape and/or be formed from steel or the like. If strength members34 are formed from steel, then the fiber optic cable is no longer adielectric design, but the cable may be able to be wrapped aroundstructures for tie-down since the steel or metal strength members have ashape memory. If fiber optic cable 30 is intended for use with pressureclamps, then strength members 34 should be suitably bonded with cablejacket 38; otherwise, cable jacket 38 may be pulled from strengthmembers 34 by pressure clamp 19 which can cause catastrophic failure. Topromote bonding with cable jacket 38, strength members 34 may includeone or more adhesion promoters 35 thereon such as selected from theethylene-acrylic family such as an ethylene-acrylic acid (EAA), butother materials or mechanisms. For instance, bonding can be mechanicalbonding by using a strength component with a rough surface or the like.Likewise, if intended for use with pressure clamp 19, strength members34 should have a spacing S of about 1 millimeter apart between innersurfaces to keep the clamped cable jacket 38 from moving into theoptical fiber zone and pressing against optical fiber 32, therebycausing elevated levels of optical attenuation. More specifically,spacing between inner surfaces of strength members 34 should be in therange of 0.8 millimeters to about 1.5 millimeters, thereby leaving awall thickness of between about 0.4 to about 0.75 disposed about asingle optical fiber when exposing and removing strength members 34 asshown in FIG. 15 a. Spacing S being relatively small also helps with therelatively large storage capacity of the fiber optic cables according tothe invention.

As discussed above, cable jacket 38 has a narrower waist portioncompared with the end portions of fiber optic cable 30 (i.e., medialheight MH is smaller than end heights EH) for inhibiting the transfer ofcrushing forces to optical fiber 32 when fiber optic cable is disposedwithin pressure clamp 19. By way of example, medial height MH is aboutbetween about 0.1 to 1.0 millimeters smaller than end height EH, andmore preferably, between about 0.2 and 0.8 millimeters smaller. A heightratio is defined as the medial height to end height (MH/EH) of the fiberoptic cable. Fiber optic cables according to the present invention mayhave a height ratio in the range of about 0.6 to about 0.9 while stillworking within pressure clamp 19, but the closer the range is to 1.0 themore optical performance is affected. Fiber optic cable 30 has a nominalheight ratio of about 0.8 (2.5 mm/3.0 mm), but this value can varywithin the range such as the height ratio being between about 0.6 (1.8mm/3.0 mm) to about 0.9 (2.7 mm/3.0 mm). In other words, the shape ofcable jacket 38 inhibits/reduces bend losses of optical fiber 32 due tocrushing forces applied by pressure clamp 19. Other variations of thefiber optic cable can have a uniform thickness for the cable jacket, butthese designs may not be suitable for use within pressure clamp 19 sinceelevated optical attenuation may occur and the optical fiber may even go“dark.” More specifically, when tensioned within pressure clamp 19 theend portions (i.e., end height EH) of fiber optic cable 30 absorb themajority of the clamping forces and reduce the clamping forcetransferred to optical fiber 32.

FIGS. 4 a-4 c show various cross-sections of fiber optic cables withinpressure clamp 19 as the height ratio changes. Specifically, FIG. 4 adepicts a cross-sectional view of fiber optic cables within pressureclamp 19 with wedge 19 c providing clamping of the cables between grip19 b and body 19 a to show the details of clamping. More specifically,FIG. 4 a shows outlines of two fiber optic cables with a height ratio of0.9 and 1.0 (e.g., the 0.9 profile is shown as a solid line and the 1.0profile) is shown as dashed line at the medial height over optical fiber32. A longitudinal section is taken along line b-b respectively throughmedial height MH of the respective fiber optic cables with two differentheight ratios as shown respectively in FIGS. 4 b and 4 c. Wedge 19 c isnot shown in FIGS. 4 b and 4 c for clarity, but pushes down on grip 19 bduring clamping. As shown by the detail in FIGS. 4 b and 4 c, grip 19 bhas dimples (not numbered) and body 19 a has ridges (not numbered) fordeforming fiber optic cable and increasing the gripping strength as thecable is being clamped therebetween. Specifically, FIG. 4 b shows thelongitudinal section of a fiber optic cable with a height ratio of 1.0and the deformation of cable jacket 48 created by the dimples of grip 19b and the ridges on body 19 a. FIG. 4 b also shows that deformationand/or forces of pressure clamp 19 affects optical fiber 32, whichaffect optical performance. Conversely, FIG. 4 c shows the longitudinalsection of a fiber optic cable with a height ratio of 0.6 and the lackof deformation of cable jacket 48 over optical fiber 32 from the dimplesof grip 19 b and the ridges on body 19 a, but other height ratios up to0.9 can also benefit by preserving optical performance. Simply stated,if the height ratio is about 0.9 or less, deformation of cable jacket 38into the optical fiber zone is reduced when disposed within pressureclamp 19. Additionally, cable jacket 38 may be formed from any suitablepolymer or blends such as a polyethylene, flame-retardant polyethylene,flame-retardant PVC, PVDF, and/or other suitable materials depending onintended use of the fiber optic cable (e.g., indoor, indoor/outdoor, oroutdoor).

FIG. 5 illustrates a graph showing an average delta optical attenuationfor fiber optic cables with different height ratios when disposed withinpressure clamp 19 at a reference wavelength of 1625 nanometers forcomparison purposes. Specifically, the graph illustrates the deltaoptical attenuation for fiber optic cable 30 (i.e., a height ratio ofabout 0.8) and a similar comparison fiber optic cable with the heightratio of one. More specifically, the graph depicts an average deltaoptical attenuation for the fiber optic cables with different heightratios in pressure clamp 19 as the tensile load on fiber optic cables isincreased from 0 pounds to 300 pounds, after the tensile load isreleased from the respective fiber optic cables with the pressure clamp19 still attached, and finally when pressure clamp 19 is removed fromthe respective fiber optic cables. The tensile load is increased up to300 pounds to model very extreme aerial installations within thepressure clamp 19 along with heavy wind and ice loading.

A line 52 and a line 54 respectively represent an average delta opticalattenuation for fiber optic cable 30 and the comparison fiber opticcable over the given tensile range and other conditions. As shown, line52 is generally flat at around 0.02 dB, which is within the noise of themeasuring equipment. For the purpose of illustration, line 52 isgenerally shown as being generally zero across the tensile range andother conditions. On the other hand, line 54 has a relatively low deltaoptical attenuation until the tensile force reaches about 175 pounds andthen dramatically increases with tensile force to unacceptable levels.After the tensile force of 300 pounds is released the attenuation stillincreases since the pressure clamp is still clamped and the cable jacketmaterial relaxes within pressure clamp 19. Additionally, if strengthcomponents are not bonded to the cable jacket the optical fiber willprobably break as the tensile force is increased to 300 pounds. Simplystated, if strength members 34 are not bonded, then pressure clamp 19causes cable jacket 38 to plastically deform by necking down on one sideof pressure clamp 19 and accordion on the other side, resulting incatastrophic failure. However, fiber optic cable 30 is advantageoussince it is robust enough to handle the extreme installation tensileloads and long spans under heavy wind and ice loads that can beexperienced in aerial installations using pressure clamp 19 withoutundue levels of optical attenuation or catastrophic failure. By way ofexample, an aerial span of 150 feet of fiber optic cable 30 experiencesa tensile load of about 220 pounds under NESC heavy loading (i.e., windand ice). The relatively low tensile load under NESC heavy conditions isdue to its relatively small cross-sectional footprint of fiber opticcable 30. Moreover, as shown by FIG. 5 fiber optic cable 30 canadvantageously handle extreme tensile loading beyond NESC heavy loadingwhile disposed within pressure clamp 19 (e.g., such as up to 300 pounds)without experiencing elevated levels of optical attenuation.

Additionally, since cable jacket 38 contacts optical fiber 32 awater-swellable or water-blocking component is not necessary since thereare no gaps (i.e., pathways) for water to migrate along fiber opticcable 30. Stated another way, cable jacket 38 is tightly drawn ontooptical fiber 32, but it does not bond to the same. It is believed thatbonding of the cable jacket 38 with to optical fiber 32 is inhibited dueto the relatively small amount of polymer required for the cable jacket38 cross-section, which cools quickly during manufacturing since it hasa relatively low amount of thermal energy to dissipate. Simply stated,the cross-section of fiber optic cable 30 is smaller because a buffertube is not required for protecting the optical fiber (i.e., no buffertube is necessary for inhibiting crushing forces and/or inhibitingsticking of the optical fiber to the cable jacket). The relatively smallamount of polymer for cable jacket 38 can be quantified using a cablejacket envelope to strength component area ratio. The cable jacketenvelope to strength component is defined as the total area of the cablejacket envelope (minus the area for the strength component(s)) to thetotal area for all of the strength components. For instance, the cablejacket envelope to strength component area ratio of fiber optic cable 30is about 4.5:1, whereas the ratio for the conventional fiber optic cableof FIG. 4 is about 5.5:1. Size variations of fiber optic cable 30 canalter the ratio to about 5:1 or less.

Optical fiber 32 should provide the desired performance for the intendedapplication. For instance, if the cable is intended for aerialapplications, then the optical fiber 32 within fiber optic cable 30should have an delta optical attenuation of about 0.3 dB or less whendisposed in pressure clamp 19 with a tensile load of 300 pounds andpreferably about 0.1 dB or less. Likewise, if the fiber optic cable hasstrength components with shape memory and is intended to be wrappedabout structures for tie-down, then optical fiber 32 should be a bendresistant optical fiber to accommodate small bend diameters as known inthe art. Additionally, if desired optical fiber 32 may include anoptional coating 33 that becomes part of the optical fiber to improvethe handability by the craft and/or robustness. By way of example,coating 33 can be any suitable material such as a UV-curable upcoatingdisposed on the optical fiber such as up to 500 microns or other desiredsize like 900 microns, but other sizes are possible like 700 microns.Polymer coatings such as a PVC, PVDF, or the like are also possible, butbonding between the polymer coating and cable jacket 38 should beavoided to preserve optical attenuation. Optical fiber 32 has arelatively low excess fiber length (EFL) such as 0.1% or less sincecable jacket 38 contacts the same and higher levels of EFL can causeelevated optical attenuation levels. Additionally, optical fiber 32 maybe proof tested to higher strength levels than normal (e.g., over 100KPSI) such as proof tested to 200 KPSI or other suitable value formaking the fiber optic cable compliant with GR-20 optical fiber strainrequirements.

Fiber optic cable designs according to the concepts of the presentinvention can have any suitable number of optical fibers therein in abare, colored, coated, or ribbonized format. FIGS. 6 and 7 respectivelyare cross-sectional views of a fiber optic cable 60 and a fiber opticcable 70 according to the present invention that are similar to fiberoptic cable 30, but the fiber optic cables include multiple opticalfibers 32. As shown fiber optic cable 60 includes two bare opticalfibers 32 disposed between strength members 34, thereby forming amulti-fiber version of the fiber optic cable. Other structures are alsopossible such as using optical fiber ribbons for creating multi-fibercable variations. Illustratively, fiber optic cable 70 depicts a fiberoptic ribbon 71 having four optical fibers 32 therein.

Additionally, tonable variations similar to fiber optic cable 30 arepossible according to the concepts of the present invention such asshown in FIGS. 8-10. Specifically, fiber optic cables according to thepresent invention can include a tonable element 81 such as a conductivewire, strip, or the like for locating the fiber optic cable such as whenit is buried so it can be located and/or marked to prevent inadvertentdamage. Tonable element 81 may be any suitable conductive materialuseful for determining the location of the fiber optic cable such as asmall copper wire, copper-clad steel, or the like. By way of example,tonable element 81 is a copper wire having a gauge between 20-42 AWG.For instance, FIG. 8 depicts a fiber optic cable 80 having a tonableelement 81 disposed within a tonable lobe 83 that is separable from amain cable body 85. Specifically, tonable lobe 83 is attached to maincable body 85 by a web 87 that is easily separable by hand, therebymaking it craft-friendly. Web 87 can also include a preferential tearportion/geometry (not numbered) for controlling the location of the tearin the web near main cable body 85, thereby resulting in a “clean”separation. Main cable body 85 and tonable lobe 83 are typicallyextruded using the same extrusion tooling. Other variations locatetonable element 81 within the main cable body. By way of example, fiberoptic cable 90 includes tonable element 81 disposed within cable jacket38 at a location near the outer surface of the same, thereby makingaccessing tonable element 81 relatively easy. Fiber optic cable 100shows another variation where tonable element is disposed within cablejacket 38, but disposed adjacent to one of the strength members 34.Fiber optic cables 90 and 100 may also include marking indicia forindicating which side of the cable includes the tonable element 81. Inother variations, tonable element 81 can be disposed within one of thestrength members or the strength component could be a tonable element.

Fiber optic cables of the present invention can be preconnectorized inthe field or the factory on one or more ends with a hardened opticconnector, thereby making a preconnectorized fiber optic cable orassembly suitable for plug and play connectivity by the craft. As usedherein, a hardened connector refers to a robust fiber optic connectorthat is weatherproof, thereby making it suitable for use in the outsideplant environment, but it is possible to use the hardened connectorindoors. For instance, the craft may route the preconnectorized fiberoptic cable having the hardened connector to a premises, a multi-portdevice, a network interface device (NID), optical network terminal(ONT), a closure, or the like. FIGS. 11 a-11 c show an exemplary fiberoptic mating assembly during the various stages of mating of an end of apreconnectorized fiber optic cable.

More specifically, FIGS. 11 a-11 c depict a preconnectorized fiber opticcable 110 (i.e., the assembly includes fiber optic cable 30 with one ormore optical connectors such as hardened connectors 150) being matedwith a complementary receptacle 130. Specifically, FIG. 11 a showsreceptacle 130 detached from preconnectorized fiber optic cable 110.Moreover, preconnectorized fiber optic cable 110 and receptacle 130 aredepicted with their respective protective caps on. Protective cap 168 isused for shielding a connector assembly 152 (FIG. 13), and inparticular, the end face of a connector ferrule 152 b of the hardenedconnector from the elements and/or damage. Specifically, installedprotective cap 168 isolates connector ferrule 152 b from the elementsand prevents it from being damaged during transportation and handling.FIG. 11 b shows protective cap 168 removed from the end ofpreconnectorized fiber optic cable 110. Likewise, the respective cap(not numbered) of receptacle 130 is also removed. Preconnectorized fiberoptic cable 110 is positioned to engage the complimentary portions ofreceptacle 130. Specifically, an alignment indicia 160 c ofpreconnectorized fiber optic cable 110 is positioned to itscomplementary indicia 130 c of receptacle 130. FIG. 11 c shows a matedconnection between the preconnectorized fiber optic cable 110 andreceptacle 130, thereby making an optical connection therebetween. Asreadily apparent, no special equipment, training, or skill is requiredto make the optical connection. Thus, the labor cost of deploying theoptical network to the premises, or other location, is cost effectiveand efficient. In this case, the mating between the hardened connector(i.e., the plug connector) and the receptacle is secured using athreaded engagement, but other suitable means of securing the opticalconnection are possible. For instance, the securing means may use aquarter-turn lock, a quick release, a push-pull latch, or a bayonetconfiguration.

FIG. 12 depicts a perspective view of an assembled preconnectorizedfiber optic cable 110′ with a toning element 81. Specifically,preconnectorized fiber optic cable 110′ is an assembly that includesfiber optic cable 80 with a hardened connector 150 (i.e., optical plugconnector) mounted upon one end of fiber optic cable 80. Recall thatfiber optic cable 80 has toning element 81 disposed within tonable lobe83 that is connected by a web portion 87 to the main cable body 85. Asshown, a portion of tonable lobe 83 is separated from main cable body 85and coiled before attaching hardened connector 150, thereby keeping itout of way and allowing grounding of tonable element 81 if necessary.Hardened connector 150 uses a connector assembly 152 of the SC type, butother types of connector assemblies such as LC, FC, ST, MT, and MT-RJare contemplated by the present invention by using a suitable crimphousing. Thus, suitable optical connectors such as hardened connectorsmay be used with suitable cables according to the concepts of thepresent invention, thereby resulting in numerous fiber opticcable/hardened connector assembly combinations.

FIG. 13 depicts a partially exploded view of preconnectorized fiberoptic cable 110 showing the components of hardened connector 150. Asshown, hardened connector 150 includes an industry standard SC typeconnector assembly 152 having a connector body 152 a, a ferrule 152 b ina ferrule holder (not numbered), a spring 152 c, and a spring push 152d. Hardened connector 150 also includes a crimp assembly (not numbered)that includes a crimp housing 155 having at least one shell 155 a and acrimp band 154, a shroud 160 (FIGS. 14 a and 14 b) that receives one ormore O-rings 159, a coupling nut 164, a cable boot 166, a heat shrinktube 167, and protective cap 168 secured to boot 166 or other suitableportion of the assembly by a lanyard 169.

Generally speaking, most of the components of hardened connector 150 areformed from a suitable polymer. By way of example, the polymer is a UVstabilized polymer such as ULTEM 2210 available from GE Plastics;however, other suitable materials are possible. For instance, stainlesssteel or any other suitable metal may be used for various components.

As best shown in FIG. 15 d, the crimp assembly includes crimp housing155 and crimp band 154. Crimp housing 155 has two shells 155 a that areheld together by crimp band 154 when the preconnectorized fiber opticcable is assembled. Although, two identical shells are shown, it is tobe understood that other suitable shell configurations are possible suchas shells that are greater than or less than half of the crimp housingor more than two shells. Crimp band 154 is preferably made from brass,but other suitable crimpable materials may be used. Crimp housing 155 isconfigured for securing connector assembly 152 as well as providingstrain relief to fiber optic cable 30 by securing one or more strengthmembers 34. Additionally, an epoxy, adhesive, glue, or the like may beused for securing strength members 34 within crimp housing 155. Thisadvantageously results in a relatively compact connector arrangementusing fewer components. Moreover, the crimp assembly allowspreconnectorized fiber cable 110 to be assembled quickly and easily. Ofcourse, other embodiments are possible according to the presentinvention. For instance, connector body 152 a may be integrally moldedinto crimp housing 155 in a ST type configuration so that a twistingmotion of the crimp housing secures the ST-type connector with acomplementary mating receptacle.

FIGS. 15 a-15 d depict several steps during the process of attaching thecrimp assembly 155 to fiber optic cable 30. FIG. 15 a shows fiber opticcable 30 with strength members 34 and optical component 42 extendingfrom the end of fiber optic cable 30. Preparing the end of fiber opticcable 30 is relatively easy since a cutting blade can be run adjacent tostrength members 34 at the top and bottom removing portion of cablejacket 38 and then strength members 34 can be pulled apart leavingoptical fiber(s) 32 encased in a portion of cable jacket 38 to provideprotection the same for routing and the like. Thereafter, the remainderof cable jacket 38 on strength members 34 can be easily removed alongwith the desired length of remaining cable jacket 38 on optical fiber(s)32. FIG. 15 b shows the inner surface of one shell 155 a. In this case,only one shell 155 a is illustrated since two symmetrical shells areused for crimp housing 155. In other embodiments there may be a firstshell and a second shell, which are different. For instance, one shellmay have two alignment pins, rather than each half-shell having a singlealignment pin or one shell may be less than half of crimp housing 155.

As shown in FIG. 15 b, shell 155 a includes a first end 155 b forsecuring connector assembly 152 and a second end 155 c that providesstrain relief by securing one or more strength members 34. Alongitudinal axis A-A is formed between first end 155 b and second end155 c of shell 155 a near the center of crimp housing 155, through whichhalf of a longitudinal passage is formed. When assembled, opticalfiber(s) 32 passes through the longitudinal passage and is held in abore of ferrule 152 b. Additionally, shell 155 a includes a cableclamping portion 156 and a connector assembly clamping portion 157.

Specifically, cable clamping portion 156 has two outboard half-pipepassageways 156 a and a central half-pipe passageway 156 b that isgenerally disposed along longitudinal axis A-A. Half-pipe passageways156 a may include at least one rib 156 c for securely clamping strengthmembers 34 and may further include injecting an epoxy, adhesive, glue,or the like into the cable clamping portions, then crimp band 154 iscrimped, thereby completing the crimp assembly. Moreover, half-pipepassageways 156 a are sized for the components of fiber optic cable 30such as strength components 34 and optical fiber(s) 32, but thepassageways can be sized for different cable configurations.

Likewise, shell 155 a has a connector assembly clamping portion 157 thatis sized for attaching connector assembly 152. Specifically, connectorassembly clamping portion 157 has a half-pipe passageway 157 a thatopens into and connects central half-pipe passageway 156 b and apartially rectangular passageway 157 b. Half-pipe passageway 157 a issized for securing spring push 152 d and may include one or more ribsfor that purpose. Rectangular passageway 157 b holds/secures a portionof connector body 152 a therein and inhibits the excess rotation betweenconnector assembly 152 and the crimp housing 155. FIG. 15 c depictsprepared fiber optic cable 30 of FIG. 15 a having connector assembly 152attached and positioned in a first shell 155 a. The alignment of the twoshells is accomplished by inserting pins 157 c into complementary bores157 d of the two shells. FIG. 15 d shows both half-shells 155 a of crimphousing 155 disposed about fiber optic cable 30 before crimp band 154 isinstalled thereover. Additionally, shells may include one or more bores156 d that lead to one of half-pipe passageways 156 a or 156 b. Bores156 d allow for inserting an epoxy, adhesive, glue, or the like into thecrimp housing 155, thereby providing a secure connection for strainrelief.

As shown in FIG. 12, when fully assembled at least a portion of thecrimp assembly fits into shroud 160. Additionally, crimp housing 155 iskeyed to direct the insertion of the crimp housing/crimp assembly intoshroud 160. In this case, shells 155 a include planar surfaces 157 e(FIG. 15 d) on opposites sides of crimp housing 155 to inhibit relativerotation between crimp housing 155 and shroud 160. In other embodiments,the crimp assembly may be keyed to the shroud using other configurationssuch as a complementary protrusion/groove or the like.

As best shown in FIGS. 14 a and 14 b, shroud 160 has a generally hollowcylindrical shape with a first end 160 a and a second end 160 b. Shroud160 generally protects connector assembly 152 and may also key hardenedconnector 150 with the respective mating receptacle 130. Shroud 160includes a through passageway between first and second ends 160 a and160 b for receiving a portion of the crimp housing. As discussed, thepassageway of shroud 160 is keyed so that crimp housing 154 is inhibitedfrom excess rotation when hardened connector 150 is assembled.Additionally, the passageway has an internal shoulder (not visible) thatinhibits the crimp assembly from being inserted beyond a predeterminedposition.

Additionally, first end 160 a of shroud 160 includes at least oneopening (not numbered) defined by shroud 160. The at least one openingextends from a medial portion of shroud 160 to first end 160 a. Morespecifically, shroud 160 includes a pair of openings on opposite sidesof first end 160 a, thereby defining alignment portions or fingers 161a,161 b. In addition to aligning shroud 160 with receptacle duringmating, alignment fingers 161 a,161 b may extend slightly beyondconnector assembly 152, thereby protecting the same. As shown in FIG. 14b, alignment fingers 161 a,161 b have different shapes so hardenedconnector 150 and receptacle 130 only mate in one orientation. Thisorientation can be marked on shroud 160 using alignment indicia 160 c sothat the craftsman can quickly and easily mate preconnectorized fiberoptic cable 110 with receptacle 130. In this case, alignment indicia 160c is an arrow molded into the top alignment finger of shroud 160,however, other suitable indicia may be used. As shown, the arrow isaligned with complimentary alignment indicia 130 c disposed onreceptacle 30 (FIG. 11 b), thereby allowing the craftsman to alignindicia 160 c,130 c so that alignment fingers 161 a,161 b can be seatedinto receptacle 130. Thereafter, the craftsman engages the externalthreads of coupling nut 164 with the complimentary internal threads ofreceptacle 130 to make the optical connection as shown in FIG. 11 c.

A medial portion of shroud 160 has one or more grooves 162 for seatingone or more O-rings 159. O-ring 159 provides a weatherproof seal betweenhardened connector 150 and receptacle 130 or protective cap 168. Themedial portion also includes a shoulder 160 d that provides a stop forcoupling nut 164. Coupling nut 164 has a passageway sized so that itfits over the second end 160 b of shroud 160 and easily rotates aboutthe medial portion of shroud 160. In other words, coupling nut 164cannot move beyond shoulder 160 d, but coupling nut 164 is able torotate with respect to shroud 160. Second end 160 b of shroud 160includes a stepped down portion having a relatively wide groove (notnumbered). This stepped down portion and groove are used for securingheat shrink tubing 167. Heat shrink tubing 167 is used forweatherproofing the preconnectorized fiber optic cable. Specifically,the stepped down portion and groove allow for the attachment of heatshrink tubing 167 to the second end 160 b of shroud 160. The other endof heat shrink tubing 167 is attached to cable jacket 38, therebyinhibiting water from entering hardened connector 150.

After the heat shrink tubing 167 is attached, boot 166 is slid over heatshrink tubing 167 and a portion of shroud 160. Boot 166 is preferablyformed from a flexible material such as KRAYTON, but other materialsand/or configurations are possible. Heat shrink tubing 167 and boot 166generally inhibit kinking and provide bending strain relief to fiberoptic cable 30 near hardened connector 150. Boot 166 has a longitudinalpassageway (not visible) with a stepped profile therethrough. The firstend of the boot passageway is sized to fit over the second end of shroud160 and heat shrink tubing 167. The first end of the boot passageway hasa stepped down portion sized for fiber optic cable 30 and the heatshrink tubing 167 and acts as stop for indicating that the boot is fullyseated. After 1 boot 66 is seated, coupling nut 164 is slid up toshoulder 160 c so that lanyard 169 can be secured to boot 166.Specifically, a first end of lanyard 169 is positioned about groove 166a on boot 166. Thus, coupling nut 164 is captured between shoulder 160 cof shroud 160 and lanyard 169 on boot 166. This advantageously keepscoupling nut 164 in place by preventing it from sliding past lanyard 169down onto fiber optic cable 30.

A second end of lanyard 169 is secured to protective cap 168 using asnap-fit into a groove (not numbered) on a front end of protective cap168. Consequently, protective cap 168 is prevented from being lost orseparated from preconnectorized fiber optic cable 110. Additionally,protective cap 168 can also include at an eyelet 168 a. Eyelet 168 a isuseful for attaching a fish-tape or other pulling device so thatpreconnectorized fiber optic cable 110 can be pulled through a duct orthe like. Protective cap 168 has internal threads for engaging theexternal threads of coupling nut 164 to secure it in place when notmaking an optical connection. Moreover, one or more O-rings 159 providea weatherproof seal between hardened connector 150 and protective cap168 when installed. When threadly engaged, protective cap 168 andcoupling nut 164 of the hardened connector may rotate with respect tothe remainder of preconnectorized fiber optic cable 110, therebyinhibiting torsional forces during pulling of the same.

Preconnectorized fiber optic cable 110 may have any suitable lengthdesired, however, preconnectorized fiber optic cable 110 can havestandardized lengths. Moreover, preconnectorized fiber optic cable 110may include a length marking indicia for identifying its length. Forinstance, the length marking indicia may be a marking located on thecable such as a colored stripe or denoted in a print statement.Likewise, the length marking indicia may be a marking located onhardened connector 150. In one embodiment, length marking indicia may bedenoted by a marking on coupling nut 164 or protective cap 168 such as acolored stripe. In any event, the length marking indicia should beeasily visible so the craftsperson may identify the preconnectorizedfiber cable length. By way of example, a red marking indicia on couplingnut 164 denotes a length of about 150 feet while an orange markingindicia denotes a length of about 300 feet.

The described explanatory embodiment provides an optical connectionbetween the hardened connector 150 and its complementary receptacle 130that can be made in the field without any special tools, equipment, ortraining. Additionally, the optical connection is easily connected ordisconnected by merely mating or unmating the ends of preconnectorizedfiber optic cable 110 with the respective receptacle by threadlyengaging or disengaging coupling nut 164 and pulling hardened connector150 from the complementary receptacle 130. Thus, the preconnectorizedfiber optic cables of the present invention allow deployment of opticalwaveguides toward the subscriber or other location in an easy andeconomical manner, thereby providing the end user with increasedbandwidth. Furthermore, the concepts of the present invention can bepracticed with other optical connectors, hardened connectors and/orother preconnectorized fiber optic cable configurations.

For instance, FIGS. 15 e and 15 f respectively depict partiallyassembled views of other optical connectors using fiber optic cable 30,which are similar, but different than hardened connector 150. Forinstance, FIGS. 15 e and 15 f depict two different embodiments whereconnector assembly 152 is integrally molded with one of the shells thatforms a portion of the housing. Other embodiments could have connectorassembly 152 integrally molded with a one piece housing. Additionally,the shroud 160 is optional for the embodiments of FIGS. 15 e and 15 fsince these embodiments are operable without the same. Simply stated,the coupling nut 164 may be sized to fit over housing 155 and disposedbetween a shoulder of the housing and cable boot 166 and a heat shrinkor the like may be used to seal between cable 30 and the connector,thereby forming the optical connector. Likewise, this constructionwithout the shroud may be practiced with the hardened connector 150shown in the Figs. Alternatively, if the features of the shroud 160 aredesired along with a smaller connector size, the mating features (i.e.,fingers 161 a,161 b) can be incorporated into a nosepiece that fits overthe front portion of the optical connector and attaches by threads,snap-fit, or the like, thereby protecting the ferrule 152 b andpolarizing the optical connector. Further, one or more O-rings may bedisposed on the connector housing and/or housing of FIGS. 15 e and 15 ffor providing an environmental seal after mating with a complementarycomponent and the embodiments may include an optional protective capand/or lanyard.

More specifically, FIG. 15 e depicts the partially assembled view of theoptical connector where connector housing 152 is integrally molded withshell 155 a′. In this embodiment, the ferrule 152 b and ferrule holderare inserted into the connector housing and then spring 152 c and springpush 152 d are then placed over the end of fiber optic cable 30 and thecable is positioned in the optical connector. Thereafter, the secondshell 155 a can be placed onto shell 155 a′ and then the remainder ofthe assembly may be assembled. FIG. 15 f depicts another opticalconnector where connector housing 152 is integrally molded with shell155 a″, which is similar to the optical connector of FIG. 15 e. In thisembodiment, shell 155 a″ forms a portion of the upper and lower portionsof housing 155. Like the embodiment of FIG. 15 e, the optical connectoremploys a ferrule 152 b, ferrule holder, spring 152 c, and a spring push152 d. Additionally, housing 155 of FIG. 15 f has a second shell 155 bthat attaches to the first shell for attaching fiber optic cable 30 tothe optical connector. Like hardened connector 150, the shells of FIGS.15 e and 15 f can be secured using crimp band 154, adhesive, epoxy,glue, or the like. Still other optical connectors, hardened connectorsand/or other preconnectorized fiber optic cable configurations arepossible.

For instance, FIG. 16 depicts an exploded view of anotherpreconnectorized fiber optic cable 210 according to the presentinvention using a hardened connector 250 attached to fiber optic cable30 that is similar to hardened connector 150. In other words, hardenedconnector 250 is suitable for mating with complementary receptacle 130like hardened connector 150, but uses a different structure for securingfiber optic cable 30 and connector assembly 52. Hardened connector 250also includes a retention body 255, a shroud 260 that receives one ormore O-rings 259, an optional shroud end piece 260 a, a coupling nut264, a cable boot 266, a heat shrink tube 254, and protective cap 268secured to boot 266 or other suitable portion of the assembly by alanyard 269.

Fiber optic cable 30 is prepared for connectorization with hardenedconnector 150 in a manner similar to that shown in FIG. 15 a. Theexposed strength members 34 of fiber optic cable are secured toretention body 255. Retention body 255 includes a central bore (notvisible) for passing optical fiber 32 of fiber optic cable 30therethrough for insertion into the ferrule of connector assembly 152.Additionally, retention body 255 has two bores disposed outboard of thecentral bore sized for receiving strength members 34 therein. One methodfor securing strength members 34 to retention body 255 uses a radiationcurable, heat curable epoxy, adhesive, glue, or the like for securingthe same. If a radiation curable substance is used such as a light or UVcurable epoxy, then retention body should be translucent for allowingthe radiation for curing to reach and cure the radiation curablesubstance in a suitable manner. The front end of retention body 255 isused for securing connector assembly 152 thereto. Specifically,connector assembly 152 snap-fits to retention body 255 using resilientfingers or the like, but other suitable structures are possible forsecuring connector assembly 152 to retention body. Additionally,connector assembly 152 may be secured to retention body 255 in a mannerthat allows for some rotational movement. Thereafter, the retention body255 assembly at least partially fits within shroud 260 and is keyed toshroud 260 inhibit rotation therebetween. The other components ofhardened connector 250 are similar to hardened connector 150.

As shown, retention body 255 is a monolithic structure, but it may havea structure that includes more that one piece. For instance, strengthmembers 34 could have a mechanical attachment to retention body 255instead of using an epoxy, adhesive, glue, or the like for securing thesame. Specifically, retention body 255 can have wedges (i.e., one-waygrips like a Chinese finger toy) that secure strength members 34 as theyare inserted into the same. Hardened connector 150 is also suitable foruse with automated assembly techniques.

Other hardened connectors can be used with the fiber optic cables of thepresent invention. FIG. 17 illustrates complementary preconnectorizedfiber optic cables 310 and 320 that are suitable for mating together.Specifically, FIG. 17 shows a partially exploded view of apreconnectorized fiber optic cable 310 using a hardened connector 350 ona first fiber optic cable 30 along with a partially exploded view of itscomplementary preconnectorized fiber optic cable 320 having hardenedconnector 390 on a second fiber optic cable 30. Hardened connector 350and 390 are similar hardened connectors (i.e., some components are thesame or similar thereby reducing complexity) that are intended to haveopposing ferrules mate through an alignment sleeve 354 that is a portionof hardened connector 350, instead of mating with a complementaryreceptacle like hardened connectors 150 and 250. In other words, acoupling nut 364 of hardened connector 350 connects to the couplingsleeve 365 of hardened connector 390 for making the optical connectiontherebetween.

Hardened connector 350 includes a spring 351, a ferrule assembly 352, aninner housing 353, alignment sleeve 354, a retention body 355, one ormore O-rings 359, an outer housing 360, a coupling nut 364, a boot 366,and a cap 368. Hardened connector 350 is similar to hardened connector250 in that it has a retention body 355 having a central bore (notnumbered) therethrough for passing optical fiber 32 therethrough andoutboard bores (not numbered) for receiving and attaching strengthmembers 34 of fiber optic cable 30 using an epoxy, glue, adhesive, orthe like. However, ferrule assembly 352 does not snap-fit to retentionbody 355; instead, spring 351 biases ferrule assembly 352 forward andinner housing 353 snap-fits to retention body 355 using resilient arms(not numbered), thereby positioning ferrule assembly 352 relative toretention body 355. Specifically, inner housing 355 includes a centrallylocated hole therethrough sized to allow a portion of the ferrule toprotrude beyond the front of inner housing 355 when assembled. As shown,hardened connector 350 includes two different sized O-rings 359. Thesmaller O-ring is sized to attach to a medial shoulder (not numbered)portion of retention body 355 and the larger O-ring is sized to attachto outer housing 360 at a medial shoulder (not numbered) for sealingportions of the hardened connector. When assembled, the retention body355 (along with the attached components) slides back into outer housing360 and is secured therein by alignment sleeve 354.

As shown, alignment sleeve 354 includes one or more resilient fingers(not numbered) that cooperates with one or more windows (not numbered)on outer housing 360 to secure the components together in the properposition. Retention body 355 is keyed to outer housing 360 usingappropriate keying geometry to inhibit rotation therebetween. Outerhousing 360 also includes a keying slot (not numbered) as best shown inFIG. 19 for aligning hardened connector 350 with hardened connector 390and alignment sleeve 354 also includes a keying portion (not visible)such as a recess that aligns with keying slot of outer housing 360.Hardened connector 350 may also include a heat shrink tubing 254 to forma seal between retention body 355 and fiber optic cable 30. Thereafter,boot 366 is attached to outer housing 36 using an epoxy, glue, adhesive,or the like, thereby keeping coupling nut 364 in place. In other words,coupling nut 364 is trapped between a shoulder of outer housing 360 anda shoulder of boot 366 while being free to rotate. When assembled, aportion of outer housing 360 extends beyond coupling nut 364 forinsertion into hardened connector 390. As shown, cap 368 can include aneyelet (not numbered) for attaching a pulling device to hardenedconnector 350 and when installed protects the end portion of hardenedconnector 350. Additionally, the assembly can optionally include alanyard (not shown) with one end secured onto boot 366 below couplingnut 364 and the other end of lanyard being attached to cap 368 forkeeping it from being lost or misplaced.

Hardened connector 390 includes many of the same components as hardenedconnector 350. For instance, hardened connector 390 includes spring 351(not visible), ferrule assembly 352, inner housing 353 (not visible),retention body 355, one or more O-rings 359, heat shrink tube (notvisible), and boot 366. Hardened connector 390 also has components thatare similar to hardened connector 350 such as a coupling sleeve 365(instead of coupling nut 364) and a cap 369 that attaches to couplingsleeve 365 for protection; however, no outer housing or similarcomponent is used. Instead, coupling sleeve 365 receives retention body355 and is keyed to the same to inhibit rotation therebetween;otherwise, hardened connector 390 is similar to hardened connector 350and assembled in a like fashion. Moreover, retention body 355 is setback a distance from the front end of coupling sleeve 365 to receive anextending portion of hardened connector 350 during mating of the twohardened connectors. Thus, the craft can quickly and easily make areliable optical connection (or break an optical connection) between theoptical fibers of the first and second fiber optic cable.

The concepts of hardened connector 350 and 390 are advantageous becausea whole family of hardened connectors can be constructed by simplychanging and/or adding a few components, thereby making the hardenedconnectors adaptable to fiber optic cables having other fiber counts.For instance, by changing the inner housings and the adapter thehardened connectors may be configured for securing more than one ferruleassembly or other types of ferrules, thereby allowingpreconnectorization of fiber optic cables having other fiber counts.

By way of example, FIG. 18 depicts complementary preconnectorized fiberoptic cables 410 and 420 that are suitable for mating together.Specifically, FIG. 18 shows a partially exploded view ofpreconnectorized fiber optic cable 410 using a hardened connector 450 ona first fiber optic cable 60 along with a partially exploded view of itscomplementary preconnectorized fiber optic cable 420 having hardenedconnector 490 on a second fiber optic cable 60. In other words, hardenedconnectors 450 and 490 are suitable for fiber optic cables having twooptical fibers 32. The components of hardened connector 450 are similarto hardened connector 350, except for inner housing 453 on both hardenedconnectors and adapter 454. Simply stated, inner housing 453 is similarto inner housing 353, but it includes two spaced apart holes forreceiving two respective ferrules 352 therethrough. Likewise, adapter454 is similar to adapter 354, but it has two spaced apart bores toallow the two ferrules of each hardened connector to mate, instead of acentrally disposed bore.

In other variations, hardened connectors similar to hardened connectors350 and 390 may include one or more multi-fiber ferrules forpreconnectorizing fiber optic cable 70 or other similar fiber opticcables. For instance, FIG. 19 depicts complementary preconnectorizedfiber optic cables 510 and 520 that are suitable for mating together.Specifically, FIG. 19 shows a partially exploded view ofpreconnectorized fiber optic cable 510 using a hardened connector 550 ona first fiber optic cable 70 along with a partially exploded view of itscomplementary preconnectorized fiber optic cable 520 having hardenedconnector 590 on a second fiber optic cable 70. In other words, hardenedconnectors 550 and 590 are suitable for fiber optic cables havingmultiple optical fibers 32 such as four, eight, twelve, or othersuitable fiber counts. The components of hardened connector 550 aresimilar to hardened connector 350, except for inner housing 553 on bothhardened connectors, spring (not visible), and adapter 554. Simplystated, inner housing 553 is similar to inner housing 353, but itincludes a rectangular opening for receiving a multi-fiber ferrule 552therethrough. Likewise, adapter 454 is similar to adapter 354, but ithas a rectangular bore to allow the rectangular multi-fiber ferrule ofeach hardened connector to mate, instead of a centrally disposed bore.Other variations of hardened connectors according to the invention arepossible such as multiple multi-fiber ferrules or the like

Many modifications and other embodiments of the present invention,within the scope of the claims will be apparent to those skilled in theart. For instance, the concepts of the present invention can be usedwith any suitable composite cable designs and/or optical stub fittingassemblies. Thus, it is intended that this invention covers thesemodifications and embodiments as well those also apparent to thoseskilled in the art.

1. A fiber optic cable assembly comprising: a fiber optic cableincluding at least one optical fiber, a first strength component, asecond strength component, wherein the first strength component and thesecond strength component are disposed on opposite sides of the at leastone optical fiber and generally aligned along a common plane, and acable jacket that contacts and is tightly drawn onto the at least oneoptical fiber, the cable jacket having a medial height disposed aboutthe at least one optical fiber that is less than an end height, wherein60 meters of the fiber optic cable can be coiled and stored in a packagehaving a volume of about 4900 cubic centimeters or less; and an opticalconnector, the optical connector being attached to an end of the fiberoptic cable.
 2. The fiber optic cable assembly of claim 1, wherein theoptical connector includes a housing having at least two shells.
 3. Thefiber optic cable assembly of claim 1, wherein the optical connectorincludes a housing having at least two shells and has a connectorhousing integrally molded into at least one of the shells.
 4. (canceled)5. The fiber optic cable assembly of claim 3, the optical connectorfurther including at least one O-ring.
 6. The fiber optic cable assemblyof claim 3, the optical connector further including a shroud.
 7. Thefiber optic cable assembly of claim 1, wherein the fiber optic cable hasa weight of about 19 kilograms or less per kilometer.
 8. The fiber opticcable assembly of claim 1, wherein the fiber optic cable has a cablejacket envelope to strength component area ratio, the cable jacketenvelope to strength component area ratio being about 5:1 or less. 9.The fiber optic cable assembly of claim 1, wherein the fiber optic cablehas a height ratio defined as the medial height to end height (MH/EH) ofthe fiber optic cable, the height ratio being in the range of about 0.6to about 0.9.
 10. The fiber optic cable assembly of claim 1, wherein aspacing between inner surfaces of first strength component and secondstrength component is in the range of 0.8 millimeters to about 1.5millimeters.
 11. The fiber optic cable assembly of claim 1, wherein thefiber optic cable has an optical attenuation of 0.3 dB or less whendisposed in a pressure clamp.
 12. The fiber optic cable assembly ofclaim 1, wherein the first strength member and second strength componentare bonded to the cable jacket using an adhesion promoter or mechanicalbonding.
 13. The fiber optic cable assembly of claim 1, wherein thefiber optic cable includes a tonable element for locating the fiberoptic cable.
 14. The fiber optic cable assembly of claim 1, wherein thefiber optic cable includes a tonable element disposed within a tonablelobe that is separable from a main cable body for locating the fiberoptic cable.
 15. The fiber optic cable assembly of claim 1, wherein theat least one optical fiber includes a buffer layer.
 16. A fiber opticcable assembly comprising: a fiber optic cable including at least oneoptical fiber, a first strength component, a second strength component,wherein the first strength component and the second strength componentare disposed on opposite sides of the at least one optical fiber andgenerally aligned along a common plane, and a cable jacket that contactsand is tightly drawn onto the at least one optical fiber, the cablejacket having a medial height disposed about the at least one opticalfiber that is less than an end height, wherein 60 meters of the fiberoptic cable can be coiled and stored in a package having a volume ofabout 4900 cubic centimeters or less; and an optical connector, theoptical connector being attached to an end of the fiber optic cable, theoptical connector includes a housing having at least two shells and aconnector housing integrally molded into at least one of the shells. 17.The fiber optic cable assembly of claim 16, the optical connectorfurther including a coupling nut.
 18. The fiber optic cable assembly ofclaim 17, the optical connector further including at least one O-ring.19. The fiber optic cable assembly of claim 18, the optical connectorfurther including a shroud.
 20. A fiber optic cable assembly comprising:a fiber optic cable including at least one optical fiber, a firststrength component, a second strength component, wherein the firststrength component and the second strength component are disposed onopposite sides of the at least one optical fiber and generally alignedalong a common plane, and a cable jacket that contacts and is tightlydrawn onto the at least one optical fiber, the cable jacket having amedial height disposed about the at least one optical fiber that is lessthan an end height, wherein 60 meters of the fiber optic cable can becoiled and stored in a package having a volume of about 4900 cubiccentimeters or less; and an optical connector, the optical connectorbeing attached to an end of the fiber optic cable, the optical connectorincluding: a housing having at least two shells and a connector housingintegrally molded into at least one of the shells; a coupling nut; aferrule; a spring; and at least one O-ring.